Disposable syringe for use with pneumatic drivers

ABSTRACT

A disposable syringe for use with a pneumatic driver. The syringe has an elongated barrel with a cap secured to the proximal end that has a through bore. A filter is secured to the cap interior of the barrel that covers an opening in the through bore interior of the barrel. The pneumatic driver includes a source of pressurized air; a support for receiving and locating the syringe; and a supply block configured to receive pressurized air from the source and having an outlet for delivery of pressurized air. The supply block is movable between a first position spaced apart from the cap of the syringe and a second position in contact with the cap with fluid communication being established between the outlet of the supply block and the through-bore in the cap.

TECHNICAL FIELD

The present disclosure is directed broadly to systems and methods for washing suspensions of biological cells. More particularly, the present disclosure is directed to systems and methods for washing small volumes of biological cells utilizing syringes actuated by pneumatic drivers for effecting movement of fluid through the system.

BACKGROUND

A number of well-known therapies are currently practiced in which a targeted cellular blood component (e.g., red blood cells, white blood cells, and platelets) is separated from whole blood and stored for later infusion to a patient. The targeted cellular product (e.g., red blood cells or platelets) may be in a suspension that includes plasma and/or some other supernatant. As such, it is sometimes desirable to “wash” the cellular suspension (typically with saline) to remove the plasma/supernatant, as well as any non-target cellular material, prior to reinfusion.

Systems and methods for cell washing are exemplified by US 2013/0341291, US 2013/0092630, and US 2014/0199680, each of which is incorporated herein by reference. Each of these published applications discloses cell washing methods utilizing systems and fluid circuits including a spinning membrane separator. Such systems include peristaltic pumps and pinch valves that act on tubing to direct flow within the fluid circuit.

The fluid circuits in the cited published applications have a relatively large internal volume, and thus require relatively large volumes of wash or flush media to clear processed fluid through the fluid circuit. While such systems and fluid circuits are capable of washing and reducing the volume of the targeted cellular component into final volumes of ranging from approximately 50 mL to 5,000 mL, there are instances in which smaller final volumes (e.g., 10 mL) are desired, such as when processing single-dose quantities of mononuclear cell products. A system and method for washing small volumes of cells is shown in US 2017/0204371, which is incorporated herein by reference.

More specifically, US 2017/0204371 discloses a fluid circuit for cell washing that comprises a spinning membrane separator and a fluid management system comprising a cassette. The cassette defines the fluid pathways, and includes internally mechanical valving, pressure sensing and air sensing for controlling flow through the fluid pathways. Additionally, the fluid circuit comprises syringes that are acted on by syringe pumps or drivers that are associated with the hardware component of the system to move the stoppers of the syringes within the syringe barrel, and thus provide pressure for moving fluid through the circuit.

US 2018/0155070, which is also incorporated by reference herein, discloses a variety of options for filling a cell product into a container, including end user containers, in which the container may take the form of a syringe. A vacuum/pressure source is associated with the syringe to move the plunger head assembly within the barrel of the syringe. Positional sensors provide signals indicative of the location of the stopper within the syringe barrel

During various stages of a washing procedure, such as that contemplated by US 2017/0204371, and a fill procedure, such as that contemplated by US 2018/0155070, suspensions of biological cells, supernatant and the like are drawn into and discharged from the barrels of the syringes. Thus, it is important to maintain the sterility of the syringes, while at the same time providing for efficient and controlled movement of the cell suspension through the system.

By way of the present application, a syringe and a pneumatic syringe driver are provided in which the pneumatic driver includes structure that locates and supports the syringe, and sealingly engages the syringe so that the stopper of the syringe can be driven without breaking sterility and opening the system.

SUMMARY

The present application has several aspects. In a first aspect, a disposable syringe is provided comprising an elongated tubular barrel having a first end and a second end, the barrel being open on the first end and tapering to a hollow tip on the second end; a cap secured to the first end of the barrel having a through-bore; a filter secured to the cap interior of the barrel and covering an opening in the through bore interior of the barrel; and a plunger head mounted to a piston and received interior of the barrel, the plunger head engaging an interior wall of the barrel and being slidable within the barrel between the first and second ends.

In a second aspect, the barrel of the syringe further comprises a collar at the first end that extends laterally from the barrel, and the cap is mounted to the collar.

In a third aspect, the tip of the syringe further comprises a luer lock.

In a fourth aspect, the through-bore in the cap of the syringe is configured to receive the tip of a second syringe.

In a fifth aspect, the cap of the syringe further comprises a luer lock extending exterior of the barrel and defining an exterior opening in the through-bore.

In a sixth aspect, the filter of the syringe is configured to form a luer lock.

In a seventh aspect, the piston of the syringe further comprises a hollow interior configured to receive the luer lock formed by the filter.

In an eighth aspect, the barrel of the syringe further comprises an annular, inwardly-projecting ridge adjacent the first end for sealingly engaging the cap.

In a ninth aspect, the cap of the syringe comprises an annular, radially-projecting seal for engaging the circumferential, inwardly-projecting ridge at the first end of the barrel.

In a tenth aspect, the syringe further comprises a gasket secured to the piston for engaging the interior wall of the barrel.

In an eleventh aspect, the cap of the syringe is removably secured to the barrel.

In a twelfth aspect, the cap of the syringe further comprises a seal encircling an opening in the through bore exterior to the barrel.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view, in partial cross section, of a pneumatic driver in combination with a disposable syringe, with the pneumatic driver in the open position, in accordance with the present application.

FIG. 2 is a side view, in partial cross section, of the pneumatic driver in combination with a disposable syringe, with the pneumatic driver in the closed position.

FIG. 3 is a side view, in partial cross section, of the pneumatic driver, with the pneumatic driver in the open position.

FIG. 4 is a side view, in partial cross section, of the pneumatic driver, with the pneumatic driver in the closed position.

FIG. 5 is a front view of the pneumatic driver in combination with a disposable syringe, with the pneumatic driver in the closed position.

FIG. 6 is an enlarged fragmentary front view of the pneumatic driver in combination with a disposable syringe, with the pneumatic driver in the closed position.

FIG. 7 is a rear view of the pneumatic driver.

FIG. 8 is a top view of the pneumatic driver, with the cover removed for clarity.

FIG. 9 is an enlarged fragmentary perspective view of the pneumatic driver in combination with a disposable syringe, with the pneumatic driver in the open position.

FIG. 10 is an enlarged fragmentary view of an alternate embodiment for an over-center latching assembly for moving the pneumatic driver into and out of sealing engagement with an associated disposable syringe.

FIG. 11 is an enlarged fragmentary cross sectional view of the upper or proximal end of a disposable syringe in accordance with the present application.

FIG. 12 is a cross-sectional view of an alternative embodiment of the assembly of the syringe cap and filter.

FIG. 13 is an enlarged cross-sectional view of further alternative configuration of the syringe cap.

FIG. 14 is a cross sectional view of the stopper received in the barrel of the syringe.

FIG. 15 is a schematic view of a disposable processing set that includes elongated syringe barrels of the type that would be used with the pneumatic driver of the present disclosure.

FIG. 16 is an enlarged view of a flow control cassette forming part of the disposable processing set of FIG. 15 .

DETAILED DESCRIPTION

A more detailed description of the systems and methods in accordance with the present disclosure is set forth below. It should be understood that the description below of specific devices and methods is intended to be exemplary, and not exhaustive of all possible variations or applications. Thus, the scope of the disclosure is not intended to be limiting, and should be understood to encompass variations or embodiments that would occur to persons of ordinary skill.

Turning to the drawings, a pneumatic syringe driver or actuator 10 is shown which may be used in combination with a disposable syringe 12. As is typical of a standard syringe, the syringe generally comprises an elongated barrel 14 having a first or proximal end and a second or distal end. The barrel is open on the first end and terminates in a hollow tip on the second end. The tip of the syringe may further be configured to comprise a luer lock 16.

The elongated barrel 14 of the syringe is preferably incorporated into a disposable processing set. A representative processing set 90 is shown in FIG. 15 . With reference to FIG. 15 , the disposable processing set 90 includes two elongated syringe barrels 92, 94, with elongated barrel 92 for the syringe that provides the motive force for the retentate, and the elongated barrel 94 for the syringe that provides the motive force for the filtrate.

The disposable processing set 90 also includes a flow control cassette 96, best seen in FIG. 16 . The flow control cassette 96 has a plurality of passageways 98 defined on the interior thereof that are in fluid communication with various of a plurality of ports 100, 102, 104, 106, 108, 110, 112, 114, 116, 118, 120, 122 on the exterior wall of the cassette 96. The outlets of the elongated syringe barrels 92, 94 are respectively connected by a tubing segment to ports 100, 102. Ports 104, 106 and 108 respectively connect the inlet, the retentate outlet and the filtrate outlet of a spinning membrane separator 124 to the cassette. Port 110 connects to a tubing segment associated with a container/bag 126 for receiving filtrate; port 112 connects to a tubing segment associated with one or more containers (not shown) of wash solution; port 114 connects to a tubing segment associated with a container (not shown) of an alternate solution depending on the application (e.g., the solution could be a cryopreservation solution); port 116 connects to a tubing segment associated with a source container (not shown); port 118 connects to a tubing segment associated with a bulk suspension bag 128; port 120 connects to a tubing segment associated with a final product container (not shown); and port 122 connects to a tubing segment associated with a vent 130. Various of the tubing segments are provided with manual pinch clamps 132, such as Roberts' clamps.

Fluid flow through the cassette 96 is controlled by a series of valves 134 that are opened and closed to selectively interconnect the passageways 98. In addition, air detectors 136 associated with ports 100, 102, 112, 114, and 116 of the cassette provide signals to a programmable controller that automatically opens and closes the valves to direct fluid through passageways and ports of the cassette.

The pneumatic driver 10 includes an air supply block 18 that sealingly engages the syringe 12 to introduce positive or negative air pressure into the barrel 14 of the syringe. The positive and negative air pressure serve to repeatedly move the stopper 20 of the syringe axially back and forth within the barrel 14 to draw fluid into the syringe (with the application of negative air pressure or a vacuum force) or to expel fluid from the barrel of the syringe (with the application of positive air pressure).

The proximal end of the syringe barrel is provided with a cap 22 having a through bore 24, through which pressurized air is introduced into the barrel of the syringe by means of the air supply block 18. Preferably, the cap 22 is removably secured to the barrel 14 to permit post-use examination of the cap 22, as described in greater detail below.

As illustrated, the barrel 14 of the syringe further comprises a collar or flanges 26 at the first end that extend laterally from the barrel (which typically provide a surface for grasping the syringe with the index finger and middle finger), and the cap 22 is mounted to the flanges 26. Further, as illustrated, the barrel 14 of the syringe is formed with an annular, inwardly-projecting ridge 28 adjacent the proximal end for sealingly engaging an annular, radially-projecting seal or gasket 30 associated with the cap 22 (as best seen in FIG. 11 ). However, alternate sealing configurations are contemplated.

Generally speaking, the pneumatic driver or actuator 10 comprises a source of pressurized air 32. As illustrated, the pneumatic source 32 comprises a compressor pump, but could alternatively comprise pressure and vacuum reservoirs or, possibly, a syringe or hand pump. The air supply block 18 is configured to receive pressurized air from the pneumatic source 32 by means of a first set of tubes 34 that connect the pneumatic source 32 to a series of valves 36, and a second set of tubes 37 that connect the valves 36 to a pressure sensor 38 (best seen in FIG. 7 ) and to the air supply block 18. A programmable controller 39 is preferably provided to automatically control air flow through the air flow pathway by turning the pneumatic source on and off and actuation of the valves 36 in response to signals received from the pressure sensor 38, and or from sensors providing positional feedback for the stopper (e.g., as described in US 2018/0155070), time limits, or other programmed behaviors.

The supply block 18 includes an outlet 40 for the delivery of pressurized air to the barrel 14 of the syringe 12 through the through bore 24 in the cap 22. To this end, the air supply block 18 is movable between a first position spaced apart from the cap 22 of the syringe (FIG. 1 ) and a second position in contact with the cap (FIG. 2 ), with fluid communication being established between the outlet 40 of the supply block 18 and the through bore 24 in the cap 22.

A seal 42 is provided between the outlet 40 of the air supply block 18 and the through-bore 24 in the cap 22 when the air supply block 18 is in the second position. Preferably, the seal 42 comprises a resilient O-ring or other compliant gasket captured in the face of the air supply block. Alternatively, the top face of the cap 18 of the syringe could include an O-ring seal or gasket that surrounds the inlet of the through bore 20. The cavity defined by the O-ring or gasket 42 is larger than the inlet in the through bore 24, thus accommodating some misalignment between the outlet of the air supply block and the inlet of the through bore. The O-ring or gasket 42 also serves to provide some tactile feedback as the air supply block 18 is brought into engagement with the cap 22, and further accommodates some planar misalignment between the mating surfaces of the air supply block and the cap. Alternatively, the outlet 40 of the air supply block 18 may comprises a luer fitting for mating with a complementary luer fitting formed by the inlet of the through bore 24 in the cap 22. Further, the luer fittings may be threaded and the supply block configured to be rotatable for coupling the luer fitting of the air supply block with that of the cap.

As illustrated, the pneumatic actuator also comprises a base 44, to which are mounted the source of pressurized air 32 and the air supply block 18. Also mounted to the base 44 is a support 46 that cooperates with the cap 22 of the syringe 12 to mount the syringe 12 to the actuator 10, with the air supply block 18 defining a longitudinal axis generally aligned with the longitudinal axis of a syringe 10 received in the support 46 when the air supply block is in the closed position. Preferably, the support 46 comprises a pair of arms that are spaced apart a distance sufficient to receive the barrel 14 of the syringe therebetween. The front or outer edges of the arms including a raised edge or shoulder 48 which serves to positively locate the cap 22 in the support 46.

The air supply block 18 is movably attached to the base 44 for movement between a first “open” position (to permit a syringe 12 to be loaded onto or removed from the support 46), and second “closed” position (in which the air supply block 18 is brought into sealing engagement with the cap 22 of the syringe 14). To this end, the air supply block 18 is mounted to the base 44 by a plurality of links 50, each link 50 having a first and second end. The first end of each link is pivotally secured to an adapter plate 44 a that is secured to the base 44 in a manner to permit the location of the adapter plate 44 a relative to the base 44 to be adjusted. For example, the base 44 may include slots for receiving threaded bolts that secure the adapter plate 44 a to the base so that the adapter plate may be moved relative to the base 44 along the slots. The second end of each link is pivotally secured to the air supply block 18.

As illustrated, two pairs of links 50 are pivotally secured to the air supply block 18 and the adapter plate 44 a, so that the links 50 of each pair are substantially parallel throughout a range of motion from the first position to the second position. Such a four link assemblage is commonly referred to as a “four-bar linkage.” The tolerances of the four bar linkage assembly may be sufficiently loose to allow for any planar misalignment between the air supply block 18 and the cap 22, while still holding the syringe 12 securely. However, the tolerances should not be so loose as to permit the user to feel the looseness.

A lever 51 is provided for moving the air supply block 18 between the open and closed positions. The lever 51 is pivotally attached to the adapter plate 44 a. A pair of further links 52 are provided, each link 52 having first and second ends, with the first end of each link 52 being pivotally secured to the lever 51 and the second end of the link 52 being pivotally secured to the air supply block 18.

Movement of the lever 51 relative to the base 44 moves the air supply block 18 between the first, open position and the second closed position. Preferably, when in the second, closed position, links 52 go over center to abut the adapter plate 44 a to act as a stop. Thus, the lever 51 and links 52 form an over-center latching mechanism. Consequently, a vertically upward force on the syringe 12 does not move the air supply block 18, while an upward force applied directly to the lever 51 will cause the links 52 to move the air supply block to the open position. As illustrated, the lever 51 is intended to be manually operated by the user. However, this could be automated.

Preferably, a cover 53 is associated with the lever 51. The cover 53 is spaced away from the base when the supply block is in the first, open position (FIG. 1 ) and is spaced closer to the base when the supply block is in the second, closed position (FIG. 2 ), so as to shield the proximal end of the syringe when it is engaged by the air supply block 18.

Alternatively, and with reference to FIG. 10 , a latch 54 may be provided for moving the air supply block 18 between the first and second positions. The latch 54 is pivotally mounted relative to the base 44 and comprises an arcuate track 56. A guide block 58 is secured to the base 44 that comprises a linear track 60 that is generally aligned with the longitudinal axis of the supply block 18. The air supply block 18 further includes a follower 62 received in both the arcuate track 56 of the latch 54 and the linear track 60 of the guide block 58, such that when the latch 54 is pivoted, the arcuate track engages 56 the follower 62 to move the follower 62 along the linear track 60, and thus move the air supply block 18 between the first and second positions. Preferably, the arcuate and linear tracks 56, 60 are in the form of slots in the latch and mounting block 54, 58, respectively, while the follower 62 is a pin forming part of the air supply block 18.

In order to maintain the air supply block 18 and lever/cover 50 in the open position to facilitate the loading of a syringe onto the support, the pneumatic driver 10 further comprises a first permanent magnet 64 secured to the base 44 and a second permanent magnet 66 secured to the air supply block 18. Preferably, the first magnet 64 is secured to the adapter plate 44 a, so that its position is adjustable. When the air supply block 18 and lever/cover 50 are in the open position, the first and second magnets 64, 66 are in sufficiently close proximity so that the force of attraction between the magnets maintains the air supply block 18 in the open position in the absence of a further external force being applied to the air supply block 18 through the lever/cover 50. The magnets 64, 66 also provide for tactile feedback of the cover being in the open position.

Turning to the disposable syringe 12 that is part of the system, as described above, the syringe 12 comprises a barrel 14 with the cap 22 having a through-bore 24 secured to the proximal end of the barrel 14. In keeping with the application, and with reference to FIG. 11 , the syringe 12 further includes a filter 68 secured to the cap 22 interior of the barrel 14 that covers the opening in the through bore 24 that communicates with the interior of the barrel. The filter 68 is such that air is considered to be sterile after passing through the filter.

More specifically, the filter 68 is a transducer protector that internally contains a hydrophobic and haemophobic membrane with a 0.2 micron pore section. Filters with this size of membrane pore are considered to be sterility filters and deliver air that is free of microbes above the 0.2 micron size. An exemplary filter is available from GVS S.p.A. of Rome, Italy, as product number TP100ACOG002AA00.

The filter 68 contains a port 70. The port 70 may be chemically bonded to the cap 22 using a solvent, such as cyclohexanone. Alternatively, the port 70 may be secured to the cap by means of screw threads, glue, ultrasonic bonding, or snap fit. In a further alternative, the cap 22 may also be configured to receive the filter membrane 68, thus eliminating the separate housing port 70.

The filter membrane 68 could be breached if the flow rate or air pressure rating is exceeded. Thus, the cap 22 and integrated filter 68 are preferably configured to allow removal of the cap 22, thus permitting evaluation of the filter 68 with a test apparatus to confirm that its integrity was maintained during use. A removable cap would also permit direct access to the stopper 20 so that a removable handle could be manually attached thereto to move the stopper in the event of a failure of the driver 10. In the illustrated embodiment, the port 70 for the filter 68 is configured to form a threaded luer lock 72 such that, upon removal of the cap 22 from the syringe 12, a filter integrity tester may be attached to the luer lock 72 to check the integrity of the filter 68.

With reference to FIG. 12 , and alternate configuration for the assembly of the syringe cap 22 and filter 68 is shown in which the filter 68 is secured to the syringe cap by means of a retainer 73, with the assembly being secured together by, e.g., ultrasonic shear welding. The syringe cap 22 and retainer 73 may be provided with ribs 22 a, 73 a, respectively, for supporting the filter 68.

A stopper, generally designated 20, is slidably received in the barrel 14 for movement within the barrel 14 between the first/proximal and second/distal ends of the barrel. As best seen in FIG. 14 , the stopper 20 comprises a plunger head 74 mounted to a piston 76. As illustrated, the piston 76 has a hollow interior sized to receive the luer lock 72 of the port 70, thus providing for a maximum volume of the filled syringe when the stopper 20 is in the fully retracted position. The piston 76 is provided with a gasket or O-ring 78 that engages the interior wall of the barrel 14 that helps to keep the piston 76 aligned with the longitudinal axis of the syringe. The plunger head 74 is provided with outer edges 80 for sealingly engages the interior wall of the barrel 14.

Optionally, the stopper may include a reflective band 82 to provide for an enhanced IR return signal used for positioning the stopper within the syringe. The shape of the curvature of the reflective band 82 may be selected to optimize the reflective signal provided by the band 82 to the sensing elements. Alternatively, the material from which the piston is made may include reflective pigment additives for this same purpose.

In the event that the pneumatic driver is unavailable, the syringe 12 as described above may be actuated manually without breaking sterility. For example, a user can draw non-sterile air into a traditional syringe with a luer fitting, attach it to the cap, and push the plunger on the traditional syringe to drive the stopper in the sterile syringe. Any source of pressurized air could similarly be attached to the cap of the sterile syringe to drive the stopper without breaking sterility. Preferably, the inlet to the through bore on the top of the cap is configured to receive the tip of a standard syringe.

As illustrated, the through bore 24 terminates in a conical portion 84 that is of the same draft angle as ISO 594-1 and 594-2 male and female luer sections. This permits the nozzle tip of a syringe to friction fit inside the conical portion 84 to allow the air in the syringe to drive the stopper 72 in the event of a power failure, thus permitting the recovery of cells trapped in the syringe 12. Alternatively, the cap 22 may be formed with a luer lock that extends exterior of the barrel of the syringe and defines the inlet to the through bore 24, thus allowing for other pneumatic systems to be connected without breaching the sterility established by the filter 68.

Thus, an improved pneumatic driver and associated syringe have been disclosed. The description provided above is intended for illustrative purposes, and is not intended to limit the scope of the disclosure to any particular method, system, apparatus or device described herein. 

The invention claimed is:
 1. A disposable syringe comprising: a) an elongated tubular barrel having a first end and a second end, the barrel being open on the first end and tapering to a hollow tip on the second end; b) a cap secured to the first end of the barrel having a through-bore; c) a filter secured to the cap and located within an interior of the barrel and covering an opening in the through-bore within the interior of the barrel; and d) a plunger head mounted to a piston and received within the interior of the barrel, the plunger head engaging an interior wall of the barrel and being slidable within the barrel between the first and second ends.
 2. The syringe of claim 1 wherein the barrel further comprises a collar at the first end and extending laterally from the barrel, and the cap is mounted to the collar.
 3. The syringe of claim 1 wherein the tip further comprises a luer lock.
 4. The syringe of claim 1 wherein the through-bore is configured to receive the tip of a second syringe.
 5. The syringe of claim 1 wherein the cap further comprises a luer lock extending exterior of the barrel and defining an exterior opening in the through-bore.
 6. The syringe of claim 1 wherein the filter is configured to form a luer lock.
 7. The syringe of claim 6 wherein the piston further comprises a hollow interior configured to receive the luer lock formed by the filter.
 8. The syringe of claim 1 wherein the barrel further comprises an annular, inwardly-projecting ridge adjacent the first end for sealingly engaging the cap.
 9. The syringe of claim 8 wherein the cap comprises an annular, radially-projecting seal for engaging the circumferential, inwardly-projecting ridge at the first end of the barrel.
 10. The syringe of claim 1 further comprising a gasket secured to the piston for engaging the interior wall of the barrel.
 11. The syringe of claim 1 wherein the cap is removably secured to the barrel.
 12. The syringe of claim 1 wherein the cap further comprises a seal encircling an opening in the through-bore exterior to the barrel. 